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Narong Sangsilaparat
HAZOP study
Over-pressure protection
Terminology
1)
2)
Over-pressure protection
Terminology
3)
4)
Over-pressure protection
Over-pressure protection
Pressure relief devices (PRV and TRV)
PRV or RV is the Pressure Relief Valve to protect equipment
and/or pipe from over pressure due to process upset
or unstable.
TRV is Thermal Relief Valve to protect liquid full system
(liquid>95%) from over pressure due to external heat
input such as sun shine, hot ambient air, steam
tracing, etc.
Over-pressure protection
Pressure relief devices
1)
Over-pressure protection
Pressure relief devices
3)
4)
Over-pressure protection
Summary of over pressure protection design
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2)
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4)
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2)
Protection by instruments
- Check valve or non-return valve to protect upstream unit (low P)
from back flow from downstream unit (High P), especially when feed
pump fail
- High pressure alarm/trip function
- Tight Shut Off Valve (TSOV) or ESD (Emergency Shut Down)
- IPF/SIL (Instrument Protective Function/Safety Integrity Level)
4)
Locking system such as lock close or lock open for the possible block
valve that can lead to overpressure. However, this is not considered
good and safe practice.
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Temperature runaway
Thermal expansion for liquid full system
External fire
Note: For fire case it is normally assumed that all feed and
product streams and other heat sources to unit are
stopped. Heat absorbed of vessel by fire can estimated
from this equation
For adequate drainage and prompt fire-fighting
Q(kw) = 43.2 * F * [Awet ]0.82
Otherwise
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Metallurgy
1.
2.
3.
4.
Low-Temperature Ductility:
Metal becomes brittle at low temperature.
Creep:
Metal deforms after under a constant load. The higher
temperature, the higher creep rate.
Embrittlement:
Cr-Mo steel becomes brittle near ambient temperature
after it has been held at high temperature for long
time.
Hot Hydrogen attack:
Steel under hot H2 is attacked to change from
carbides to iron : Fe3C + 2H2 CH4 + 3Fe
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Corrosion
1. Electro-Chemical Corrosion or Aqueous Corrosion
Iron Rust
2. Stress Corrosion Cracking
- Stainless Steel in hot chloride containing water
- Carbon steel in hot caustic solution
- Copper alloys in ammonia containing media
3. Dew point corrosion
Corrosion by SO2/SO3 in flue gas when temperature
drop below 140-160 degC
4. Corrosion Under Insulation (CUI)
Corrosion outside pipe surface if water trapped in
insulation
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Piping class
Cause of pipe failure
Corrosions
Dead legs or stagnant part that can lead to
microbial growth and start corrosion process
Cavitations or hammering
Pressure surge when flow suddenly change
Vibration
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Piping
Identification of piping
Example 150-P23017-31010
150
Nominal
Diameter
(mm)
P 23 017 3
01
Unit No.
Pipe
Material
0
Variation
No.
Line no.
Fluid type
ANS class
rating
Service
Limitations
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Piping
PROCESS
INERT GAS
STEAM/CONDENSATE
WATER
AIR
DRAIN
FUEL
REFRIGERATION
BLOW-DOWN and RELIEF
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Piping
barg@50 C
19.3
50.0
100.0
150.0
250.5
415.0
Type of units
CDUs, SWS, Utilities
Debut./Depro./LPG treating
HDT/HDS, TCU, HP steam
HCU
HCU/HyCON
HCU/HyCON
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Piping
Carbon Steel
Low & Intermediate Alloy Steel
Stainless Steel
Aluminium & Al.Base Alloys
Copper & Copper Base Alloys
Nickel & Nickel Base Alloys
Non-metallic materials
Carbon steel with LINING
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sec
sec
sec
m
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Equipment Arrangements
EFD or PEFS or P&ID is a pictorial representation of a plant
which shows all the equipment, including spare and
the associated piping, valve, instrumentation, heat
tracing and insulation.
Note: Before doing HAZOP we shall have EFD in order to
know the arrangement of equipment and consequence
of any failure.
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1) Pressure vessel
-
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2) Heat Exchanger
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2) Heat Exchanger-Horizontal HE
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Piping
- Vent and drain on Heat Exchanger shell should be avoid as
much as possible except
on shell cover of horizontal floating head
on shell cover of vertical floating head
process reason such as inert venting on the line is not
able to do.
- Vent and drain with valve and blind flange shall be installed
on piping of sizing DN40 minimum.
- Isolation valve and by-pass can be installed for
maintenance purpose but need separate PRV on individual
pressure loop.
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Apply 2/3 rule if isolation of both high and low pressure side is
possible. 2/3 rule is designed of low pressure side at 2/3 times of
the high pressure side.
Apply 2/3 rule or install PRV when isolation of high pressure side
is only possible.
Excessive fouling
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3) Pump
-
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- Suction line shall not be routed higher than lowest level of liquid
supply.
- Each pump shall have isolation block valve with spectacle blind both
suction side (upstream strainer) and discharge side.
- Each pump shall have strainer either Y strainer or bucket strainer.
- Warm up steam or heat tracing for spare pump for viscous oil service
may apply.
- TSOV at the suction in case service LPG or hydrocarbon above its
auto-ignition temperature.
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4) Compressor
-
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Equipment Protection
- PRV at discharge of reciprocating compressor shall be installed
upstream of the block valve to safeguard against block outlet and
normally be routed to flare.
- Safeguarding to trip compressor shall have
- High liquid level in knock-out drum
- High discharge temperature for each cylinder
- Low suction pressure
- Low lube oil pressure
- High speed of turbine
- High surge pressure
- Low discharge flow
- High differential pressure for reciprocating
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Standard isolation
Positive isolation
Special function of valve
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Standard isolation
- Single valve isolation: sufficient for equipment
isolation that pressure level lower than 100 bar at
ambient temp
- Double valve isolation
Two valve in series in case of no small leak
allowed
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Positive isolation
Positive isolation is to guaranteed physical separation
between systems
- Spade is normally used for temporary isolation.
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HAZOP Study
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Deviation
Project No.:
Possible causes
Title :
Unit No.:
Consequences
Protection
Area:
Action by
No flow
More flow
Less flow
Reverse flow
High temp
Low temp
High pressure
Low pressure
Others
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Example of Hazop
Proposal No.: 07048
Deviation
No flow
Area: D
Protection
Action by
- P-3301A damage
Work instruction
Op
- P-3301A damage
Work instruction
Op
-P-3301A trip
op
Work instruction
Op
- P-3301A damage
Work instruction
Alarm SOV openning status
Op
More flow
op
Less flow
- Partially open/Throttled
Operator monitoring
op
Operator monitoring
op
Operator monitoring
op
Reverse flow
- Wrong line up
Product contamination
op/excise/security
High temp
N/A
Low temp
N/A
High pressure
- Thermal expansion
leak at flange
Product contamination
Low pressure
Contamination
Others
op
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